Case Study: How a Leading Doughnut and Pastry Manufacturer in the Philippines Revolutionized Flour Handling with Advanced Sieving Solutions

Overview

Flour and ingredient handling is the key to maintaining consistent quality and efficiency in the food sector. The growing market demands led to production challenges for one of the premier makers of doughnuts, pastries, and premixes in the Philippines. The problems were such that operations, as well as the end products, suffered from things such as ineffectiveness of manual handling, spillage, and inaccurate weighing of the ingredients. To address these challenges, they sought a reliable flour sieving solution capable of handling multiple ingredients like wheat flour, sugar powder, and salt while ensuring precision and hygiene.

Recognizing the need for a comprehensive approach, the client partnered with Galaxy Sivtek in the Philippines, resulting in a transformative solution that optimized their ingredient handling and production processes.

Requirements & Challenges

The client reached out to Galaxy Sivtek to address several challenges that were impacting their production efficiency:

1. Manual Handling of Flour and Ingredients: The client was completely dependent on manual processes, which require more labor and are inefficient.
2. High Dependency on Manpower: The production line always required 4-5 workers, resulting in higher operational costs and a greater chance of errors.
3. Product Loss Due to Spillage: Manual handling operations led to product loss due to spillage, which in turn affected the company’s profitability.
4. Inaccurate Weighing: The weighing process was not accurate and varied, that led to quality differences of the products, where each batch had a different taste.
5. Hygiene Standards: The client had to comply with CGMP (Current Good Manufacturing Practices) and noise emissions of less than 80dB.

Through their partnership with Galaxy Sivtek, the client aimed to achieve specific objectives, such as reducing manpower requirements, eliminating spillage, improving accuracy in batching, and upholding high hygiene standards.

Solution

Galaxy Sivtek provided a comprehensive, integrated solution for flour and ingredient handling tailored to the client’s needs. The proposed solution included:

1. Bag Dump Station with Dust Collection: An advanced system designed for the safe dumping of flour bags, minimizing dust and maintaining hygiene.
2. Mechanical Conveying System: Automated conveyors moved ingredients from the dumping station to the flour sieving solution, reducing the need for manual handling.
3. Flour Sieving Solution: Featuring the GS (Gyro Sifter) series machine, this state-of-the-art flour sieving solution ensured the purity of wheat flour, sugar powder, and salt, followed by a storage hopper that maintained quality.
4. High Precision Weighing: The solution equipped load cells of high precision and fine feed valves for efficient weighing of ingredients, thus ensuring batch consistency.

These solutions collectively addressed the client’s challenges, streamlining their production processes and enhancing overall efficiency.

Results

The implementation of Galaxy Sivtek’s solutions led to significant improvements in the client’s operations:

1. Enhanced Efficiency: The automated systems significantly cut down the time and labour needed for flour handling, enabling better resource allocation.
2. Zero Spillage: The transition to automated processes effectively eliminated product loss due to spillage, maximizing the use of raw materials.
3. Consistent Product Quality: With accurate weighing and the Gyro Sifter series machine for flour sieving, the client achieved consistency in taste and quality across all production batches, strengthening their brand reputation.
4. Satisfaction and Growth: The client expressed immense satisfaction with the results, which led to discussions about two additional projects with Galaxy Sivtek for their subsidiaries in other countries.

Conclusion

This case study illustrates the transformative impact of Sivtek’s integrated flour-sieving solutions for a leading flour handling client in the Philippines. Addressing their specific problems and adjusting to their operational objectives, the solution improved production efficiency, yet more crucially kept the product quality and hygiene at very high standards. This successful collaboration showcases the commitment to providing innovative solutions that cater to the specific needs of clients in the food processing industry, paving the way for continued growth and success.